Vacuum glazing pillars delivery films and methods for insulated glass units

ABSTRACT

Pillar delivery films for vacuum insulated glass units. The delivery films include a support film or pocket tape, a sacrificial material on the support film, and a plurality of pillars. The pillars are at least partially embedded in the sacrificial material or formed within sacrificial material molds, and the sacrificial material is capable of being removed while leaving the pillars substantially intact. In order to make an insulated glass unit, the delivery films are laminated to a receptor such as a glass pane, and the support film and sacrificial material are removed to leave the pillars remaining on the glass.

BACKGROUND

Windows are poor thermal insulators and contribute significantly tobuilding heat loss and energy inefficiency. The need to meet greenbuilding standards is driving the adoption of energy efficient insulatedglass units including vacuum designs. A vacuum insulated glass unit 10is shown in FIGS. 1 and 2. Unit 10 includes two panes of glass 11 and 12separated by a vacuum gap. Pillars 14 in the gap maintain the separationof glass panes 11 and 12, which are hermetically sealed together by anedge seal 13, typically a low melting point glass frit, surrounding thepillars. Manufacturing vacuum insulated glass units efficiently and costeffectively can present challenges, particularly with selection ofsuitable pillars, placement of the pillars, and sealing the glass panestogether with the vacuum gap. Accordingly, a need exists for improvedways to make and install pillars for vacuum insulated glass units.

SUMMARY

A pillar delivery film, consistent with the present invention, includesa support film, a sacrificial material layer on the support film, and aplurality of pillars. Each pillar is at least partially embedded in thesacrificial material layer, which is capable of being removed from thepillars while leaving the pillars substantially intact.

Another pillar delivery film, consistent with the present invention,includes a support film, a plurality of molds on the support film, and aplurality of pillars located in the molds. The molds are composed of asacrificial material, which is capable of being removed from the pillarswhile leaving the pillars substantially intact.

A pillar delivery pocket film, consistent with the present invention,includes a support film having a plurality of pockets formed within itand a plurality of pillars located in the pockets. The support film iscomposed of a sacrificial material, which is capable of being removedfrom the pillars while leaving the pillars substantially intact.

Another pillar delivery pocket film, consistent with the presentinvention, includes a support film having a plurality of pockets formedwithin it, a sacrificial material located within the pockets, and aplurality of pillars at least partially embedded in the sacrificialmaterial in the pockets. The sacrificial material is capable of beingremoved from the pillars while leaving the pillars substantially intact.

A method for transferring pillars from a delivery film to a receptorsurface, consistent with the present invention, includes providing adelivery film having a support film, a sacrificial material on thesupport film, and a plurality of pillars at least partially within thesacrificial material. The delivery film is laminated to a receptorsurface with the pillars facing the receptor surface. The support filmis removed while leaving the pillars on the receptor surface and atleast a portion of the sacrificial material on the pillars. Thesacrificial material is then removed while leaving the pillars remainingand substantially intact on the receptor surface.

A method for making a delivery film having pillars and transferring themto a receptor surface, consistent with the present invention, includesproviding a support film with a releasable surface. A plurality ofpillars are molded on the releasable surface of the support film using amold applied to the releasable surface, and the mold is removed from thereleasable surface while leaving the pillars substantially intact. Thepillars are then transferred from the support film to a receptorsurface.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated in and constitute a part ofthis specification and, together with the description, explain theadvantages and principles of the invention. In the drawings,

FIG. 1 is an exploded perspective view of a vacuum insulated glass unit;

FIG. 2 is a side sectional view of a vacuum insulated glass unit;

FIG. 3 is a diagram of a pillar delivery film for transfer to asacrificial material layer;

FIG. 4 is a diagram of a pillar delivery film for transfer to asacrificial material layer;

FIG. 5 is a diagram of a pillar delivery film and method for transferdirectly to glass;

FIG. 6 is a diagram of a pillar delivery film and method for transfer toa sacrificial material layer;

FIG. 7 is a diagram of a pillar delivery film and method having asacrificial material mold on a support film;

FIG. 8 is a diagram of a pillar delivery film and method for transfer toa sacrificial material layer on a support film;

FIG. 9 is a diagram of a pillar delivery film and method for transfer toa sacrificial material layer on a support film;

FIG. 10 is a diagram of coated pre-formed pillars;

FIG. 11 is a top view of pocket tape for delivering pillars;

FIG. 12 is a side sectional view of a portion of the pocket tape;

FIG. 13A is a side sectional view of pocket tape having pre-formedpillars;

FIG. 13B is a perspective view of the pillar resulting from the pockettape of FIG. 13A;

FIG. 14A is a side sectional view of pocket tape having curedform-in-place pillars;

FIG. 14B is a perspective view of the pillar resulting from the pockettape of FIG. 14A;

FIG. 15A is a side sectional view of pocket tape having curedform-in-place pillars with adhesive;

FIG. 15B is a perspective view of the pillar resulting from the pockettape of FIG. 15A;

FIG. 16A is a side sectional view of pocket tape having curedform-in-place pillars with retention rings;

FIG. 16B is a perspective view of the pillar resulting from the pockettape of FIG. 16A;

FIG. 17A is a side sectional view of sacrificial pocket tape havingcured form-in-place pillars;

FIG. 17B is a perspective view of the pillar resulting from the pockettape of FIG. 17A;

FIG. 18A is a side sectional view of carrier film and sacrificial pockettapes having cured form-in-place pillars;

FIG. 18B is a perspective view of the pillar resulting from the pockettape of FIG. 18A;

FIG. 19A is a side sectional view of a pocket tape having curedform-in-place pillars in sacrificial pockets;

FIG. 19B is a perspective view of the pillar resulting from the pockettape of FIG. 19A;

FIG. 20 is a diagram of a pillar delivery film and method using astrippable tool;

FIG. 21 is a diagram of a pillar delivery film and method using astrippable tool with a sacrificial material layer;

FIG. 22 is a diagram of a pillar delivery film and method using a rotarytool; and

FIG. 23 is a diagram of a pillar delivery film and method using astrippable skin.

DETAILED DESCRIPTION

Embodiments of the present invention include pillar delivery films andmethods that can be used to provide the pillars required for fabricationof vacuum insulated glass units. The delivery films contain the pillars,and the methods can use the films to place the pillars on glass panes.One method involves mechanically depositing the pillars onto a pocketfilm or a film with a releasable surface and lamination transferring thepillars onto glass. Another method involves molding the pillars in placeon a pocket film or a film with a releasable surface and mechanicallytransferring the pillars to glass. Another method involves molding thepillars in place on a pocket film or a film with a releasable surfaceand lamination transferring the pillars onto glass. The mechanicaltransfer of pillars, referred to as pick and place, can use robotics forthe movement and placement of the pillars. The mold in place of thepillars and lamination transfer of them are described below. The methodscan also deliver the edge seal in the glass units. The delivery filmsand methods can make use of lamination transfer films.

Examples of pillars for vacuum insulated glass units are described inU.S. Patent Application Publ. No. 2015/0079313, which is incorporatedherein by reference as if fully set forth. Examples of laminationtransfer films are described in U.S. Patent Application Publ. No.2014/0021492, which is incorporated herein by reference as if fully setforth.

FIG. 3 is a diagram of a pillar delivery film with a sacrificialmaterial layer for transfer to glass. The delivery film includes asupport film 16, a sacrificial resin material 17 forming molds, and formin place pillars 18. The pillars can optionally include a pre-formedpillar body 15.

FIG. 4 is a diagram of a pillar delivery film with a sacrificialmaterial layer for transfer to glass. The delivery film includes asupport film 19, a sacrificial resin material 20 can be a continuous ordiscontinuous layer on support film 19, pre-formed pillars 21, and anoptional functional layer 22 on or around the pillars. As illustrated,pillars 21 can be on or at least partially embedded within material 20.The pillars can optionally include pre-formed pillar bodies 15.

FIG. 5 is a diagram of a section of a pillar delivery film and methodfor transfer directly to glass. The delivery film includes a supportfilm 24 having a mold 25. The mold is filled with a curable pillar resin26 to form a filled mold on the support film (step 30). Alternatively apreformed pillar may be inserted into the mold before or after thecurable resin fill. The support film is laminated to glass 27 (step 31),and the film and glass laminate is cured (step 32). Film 24 with mold 25is removed (step 36), resulting in pillar 26 on glass 27. Alternatively,a molded pocket tape 28 can be used. Pocket tape 28 is filled with acurable pillar resin to form pillar 26 (step 33). The filled pocket tape28 is laminated to glass 27 (step 34), and tape and glass laminate iscured (step 35). Pocket tape 28 is removed (step 36), resulting inpillar 26 on glass 27.

FIG. 6 is a diagram of a section of a pillar delivery film and methodwith a sacrificial material layer for transfer to glass. Mold 41 canoptionally be on mold support film 40. The mold is filled with a curablepillar resin 42 to form a filled mold (optionally on mold support film40) (step 50). Mold 41 (or optionally mold support film 40) is laminatedto transfer film 44 having a sacrificial material layer 43 (step 51),and the mold (optionally be on mold support film 40) and transfer film44 laminate is cured (step 52). Mold 41 or optionally be on mold supportfilm 40 is removed (step 56), resulting in pillar delivery filmcomprising pillar 42 on transfer film 44 with sacrificial material 43between them. Alternatively, a molded pocket tape 45 can be used. Pockettape 45 is filled with a curable pillar resin to form pillar 42 (step53). The filled pocket tape 45 is laminated to transfer film 44 havingsacrificial material layer 43 (step 54), and pocket tape and transferfilm 44 laminate is cured (step 55). Pocket tape 45 is removed (step56), resulting in pillar delivery film comprising pillar 42 on transferfilm 44 with sacrificial material 43 between them.

FIG. 7 is a diagram of a section of a pillar delivery film and methodhaving a sacrificial material mold on a support film. The delivery filmincludes a mold support film 60 having a sacrificial material mold 61.The mold support film 60 may be the sacrificial mold 61. Mold 61 isfilled with a curable pillar resin 62 to form a filled mold on moldsupport film 60 (step 70). The resin material is cured (step 71), anduncured pillar resin is deposited on the cured resin material (step 72).Mold support film 60 is laminated to glass 63 (step 73), and the filmand glass laminate is cured (step 74). Mold support film 60 is removed,leaving sacrificial material mold 61 on resin pillar 62 (step 75). Thesacrificial material is baked out (step 79), resulting in pillar 62 onglass 63. Alternatively, mold support film 60 is laminated to glass 63without the uncured pillar resin (step 76), and the film and glasslaminate is cured (step 77). Mold support film 60 is removed, leavingsacrificial material mold 61 on resin pillar 62 (step 78). Thesacrificial material is baked out (step 79), resulting in pillar 62 onglass 63.

FIG. 8 is a diagram of a section of a pillar delivery film and methodfor transfer to a sacrificial material layer on a transfer film andlamination to glass. A support film 80 includes a release surface orcoating 81. Using a continuous cast and cure process, a pillar 82 isformed on support film 80 (step 90), and support film 80 with pillar 82is laminated to a transfer film 83 having a sacrificial material coating84 (step 91). Support film 80 is removed, transferring pillar 82 totransfer film 83 (step 92). An optional adhesive 85 can be applied topillar 82 (step 93). Transfer film 83 is laminated to glass 86 (step94), and transfer film 83 is removed (step 95). Sacrificial material 84is removed (step 96), resulting in pillar 82 on glass 86 with optionaladhesive 85. As illustrated, pillars 82 can be partially embedded withinoptional adhesive 85.

FIG. 9 is a diagram of a section of a pillar delivery film and methodfor transfer to a sacrificial material layer on a support film. Thedelivery film includes a support film 100 with a release surface orcoating 102. Using a continuous cast and cure process, a pillar 103 isformed on support film 100 (step 110) with a pillar land 106 betweenpillars, and an adhesive 104 is deposited on pillar 103 (step 111).Support film 100 with pillar 103 is laminated to glass 105 (step 112).Support film 100 is removed (step 113), resulting in removal of pillarland 106 and transfer of pillar 103 to glass 105 with adhesive 104.

FIG. 10 is a diagram of coated pre-formed pillars. A pre-formed pillar120 is coated in a wet or dry coating process (step 123) to form acoating 121 surrounding pillar 120. The coated pillar can then betransferred to glass 122 using, for example, the methods describedabove. Additional functional layers can also be optionally added to thecoated pillar. Coating 121 can include, for example, an adhesivecoating, an silsesquioxane precursor with nanoparticles, or a polymerderived ceramic.

FIG. 11 is a top view of pocket tape 130 for delivering pillars. Pockettape 130 typically includes holes 131 to engage machine gears. Materialpockets 132 are formed in pocket tape 130. FIG. 12 is a side sectionalview of a portion of the pocket tape 130 having pockets 132. Pocket 132includes a film portion 133 and a pocket portion 134 for using informing, transferring, and delivering, pillars.

FIGS. 13A-19A are side sectional views of various pocket tapes used toform pillars, and FIGS. 13B-19B are perspective views of the resultingpillars. FIG. 13A is a side sectional view of a pocket tape 140 havingpre-formed pillars 141 (FIG. 13B). FIG. 14A is a side sectional view ofa pocket tape 142 having cured form-in-place pillars 143 (FIG. 14B).FIG. 15A is a side sectional view of a pocket tape 144 having curedform-in-place pillars 145 with an adhesive 146 (FIG. 15B). FIG. 16A is aside sectional view of a pocket tape 147 having cured form-in-placepillars 148 with adhesive 151 and adhesive retention rings 149 to limitthe lateral spread of the adhesive (FIG. 16B) and a liner 150. FIG. 17Ais a side sectional view of a pocket tape 151, formed from a sacrificialmaterial, having cured form-in-place pillars 152 (FIG. 17B). FIG. 18A isa side sectional view of carrier film tape 153 and a sacrificial pockettape 155 having cured form-in-place pillars 154 (FIG. 18B). FIG. 19A isa side sectional view of a pocket tape 156 having cured form-in-placepillars 157 in pockets formed from a sacrificial material 158 (FIG.19B).

FIG. 20 is a diagram of a section of a pillar delivery film and methodusing a strippable tool 160 composed of a strippable film molds 161. Thedelivery film includes a support film 162 having a sacrificial material163. Strippable tool 160 is laminated to support film 162 to createmolds (step 170), and a curable pillar paste 164 is coated onto supportfilm 162 (step 171), creating curable pillar 164A and land 164B. Thefilled support film 162 is cured (step 172), and an adhesive 165 iscoated onto cured pillar 164 (step 173), creating an adhesive coating165A on the cured pillar 164A and an adhesive coating 165B on the curedland 164B. Strippable tool 160 is removed (step 174), taking with itcured land 164B and adhesive 165B, resulting in zero land pillartransfer film having pillar 164A on sacrificial material 163 andadhesive 165A.

FIG. 21 is a diagram of a section of a pillar delivery film and methodusing a strippable tool 180 composed of a strippable film molds 181 witha sacrificial material layer 183. The delivery film includes a supportfilm 182. Strippable tool 180 is laminated to support film 182 (step190), and a curable pillar paste 184 is coated onto support film 182(step 191), creating curable pillar 184A and land 184B. The filledsupport film 182 is cured (step 192), and an adhesive 185 is coated ontocured pillar 184 (step 193), creating an adhesive coating 185A on thecured pillar 184A and an adhesive coating 185B on the cured land 184B.Strippable tool 180 is removed (step 194), taking with it cured land184B and adhesive 185B, resulting in a zero land pillar transfer filmhaving pillar 184A and sacrificial material 183 on support film 182 andadhesive 185A on pillar 184A.

FIG. 22 is a diagram of a pillar delivery film and method using a rotarytool having an opaque perforated rotary mold tool 200 and curing units201. The delivery film includes a support film 204 having a sacrificialmaterial 205. A pillar material 206 is applied to support film 204through perforated rotary mold tool 200 and cured by curing units 201(step 210), resulting in formed pillars on support film 204 when removedfrom perforated rotary mold tool 200 (step 211). An adhesive 207 iscoated on pillar 206 (step 212), resulting in zero land pillar transferfilm having pillar 206 on sacrificial material 205 and support film 204and with adhesive 207.

FIG. 23 is a diagram of a section of a pillar delivery film and methodusing a strippable skin, which is a type of strippable tool. Thedelivery film includes a structured film mold 220 with a strippable skin222 or a replicated resin mold 221 on film 220 with strippable skin 222.A curable pillar paste 223 is coated onto the mold film 220 (step 230),creating curable pillar 223A and land 223B, the filled mold film 220 iscured (step 231), and an adhesive 224 is coated on cured pillar 223(step 232), creating an adhesive coating 224A on the cured pillar 223Aand an adhesive coating 224B on the cured land 223B. Strippable skin 222is removed (step 233), taking with it cured land 223B and adhesive 224B,resulting in a zero land pillar transfer film having pillar 223 onsupport film 220 and with an adhesive 224.

In the fabrication processes described above, additional or supplementalsteps can be used within the described steps. In the processes describedabove, or other processes of the present invention, the sacrificialmaterial can be removed by being cleanly baked out or by being otherwisecapable of removal. The term “cleanly baked out” means that thesacrificial material can be removed by pyrolysis or combustion withoutleaving a substantial amount of residual material such as ash. In someof the side sectional views of the delivery films described above, onlyone mold and corresponding pillar are shown for illustrative purposesonly. The delivery films typically include many of the molds and pillarsfor delivery of the pillars to vacuum insulated glass units.

Exemplary materials for the processes described above are provided inthe Examples. Exemplary materials for the pillars for the vacuuminsulated glass units include the following: ceramic nanoparticles;ceramic precursors; sintered ceramic; glass ceramic; glass frit; glassbeads or bubbles; metal; or combinations thereof.

EXAMPLES

Materials Abbreviation or Available Trade Designation Description fromFILTEK Supreme+ paste 3M Company, 5032W 2009-04 St. Paul, MN QPAC 40 poly(alkylene carbonate) Empower Materials, Inc., copolymer New Castle,DE QPAC 100 poly(alkylene carbonate) Empower Materials, Inc., copolymerNew Castle, DE QPAC 130 poly(alkylene carbonate) Empower Materials,Inc., copolymer New Castle, DE T50 silicon release liner Solutia Inc.,St. Louis, MO

Example 1 Replicated Mold of Sacrificial Material

A coating solution was prepared by dissolving enough of QPAC 40 in1,3-dioxolane to produce a final weight percent of 30% QPAC 40. Thecoating solution was hand coated on the backside of a 0.051 mm (0.002inch) thick T50 silicone release liner in a notch bar coater.Approximately 50 milliliters of the coating solution was applied to theT50 backside and pulled through a notch bar coater set with a gap of0.024 inches. The coating was dried at ambient for 1 hour.

The coated film was placed on a hotplate coating side up and held at 50°C. until heated. A tool containing square protrusions on a 0.132 cmpitch was placed onto the coated film, protrusion side down. Individualsquare posts on this tool tapered at 6 degrees from 296 um at the baseto 227 um at the top, and were 305 um tall. A 4.6 kg weight was placedonto the top of the tool, embossing the coating. The tool was allowed tocontact the film at temperature for 5 minutes. The weight was removedfrom the tool and the assembly was removed from the hotplate, andallowed to return to room temperature. The tool was then removed. Thecoated film now contained wells in the coating that corresponded to theprotrusions on the tool.

The wells in the film were then filled with FILTEK Supreme+ 5032W2009-04 by applying the FILTEK Supreme+ paste to the film and doctoringoff the excess with a spatula. The filled sample was then laminated to aclean glass slide at room temperature with a silicone hand roller. Theresulting laminate was then cured under germicidal lamps for fiveminutes. The T50 liner was then removed, leaving cast posts attached tothe glass slide, surrounded by the sacrificial mold.

Example 2 Replicated Mold of Sacrificial Material with Adhesive

A coating solution was prepared by dissolving enough of QPAC 40 in1,3-dioxolane to produce a final weight percent of 30% QPAC 40. Thecoating solution was hand coated on the backside of a 0.051 mm (0.002inch) thick T50 silicone release liner in a notch bar coater.Approximately 50 milliliters of the coating solution was applied to theT50 backside and pulled through a notch bar coater set with a gap of0.024 inches. The coating was dried at ambient for 1 hour.

The coated film was placed on a hotplate coating side up and held at 50°C. until heated. A tool containing square protrusions on a 0.132 cmpitch was placed onto the coated film, protrusion side down. Individualsquare posts on this tool tapered at 6 degrees from 296 um at the baseto 227 um at the top, and were 305 um tall. A 4.6 kg weight was placedonto the top of the tool, embossing the coating. The tool was allowed tocontact the film at temperature for 5 minutes. The weight was removedfrom the tool and the assembly was removed from the hotplate, andallowed to return to room temperature. The tool was then removed. Thecoated film now contained wells in the coating that corresponded to theprotrusions on the tool.

The wells in the film were then filled with FILTEK Supreme+ 5032W2009-04 by applying the FILTEK Supreme+ paste to the film and doctoringoff the excess with a spatula. The resulting laminate was then curedunder germicidal lamps for five minutes. A second layer of FILTEKSupreme+ 5032W 2009-04 by applying the FILTEK Supreme+ paste to the filmand doctoring off the excess with a spatula, leaving a thin layer ofuncured FILTEK Supreme+ paste on top of the cured layer, impartingadhesion to the sample.

The sample was then laminated to a clean glass slide at room temperaturewith a silicone hand roller. The resulting laminate was then cured undergermicidal lamps for five minutes. The T50 liner was then removed,leaving cast posts attached to the glass slide, surrounded by thesacrificial mold.

Example 3 Particle Delivery Film

A coating solution was prepared by dissolving enough of QPAC 40 in 1-3dioxolane to produce a final weight percent of 5% QPAC 40. The coatingsolution was delivered at a rate of 30 cm³/min to a 10.2 cm (4 inch)wide slot-type coating die. After the solution was coated on thebackside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, thecoated web traveled approximately 2.4 m (8 ft) before entering a 9.1 m(30 ft) conventional air floatation drier with all 3 zones set at 65.5°C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10ft/min) to achieve a wet coating thickness of about 80 micrometers.

A piece of the coated film slightly larger than 6 in×6 in was placed ona hotplate held at 50° C. Grade 36+ shaped abrasive particles preparedaccording to the disclosure of U.S. Pat. No. 8,142,531 having a sidelength of about 0.8 mm and about 0.2 mm thick, and a sidewall angle of98 degrees. The particles were pressed into the heated film in a gridwith 2 cm spacing, creating a particle delivery film. The particledelivery film was removed from the hotplate and brought to roomtemperature.

The cooled particle delivery film was laminated at 230 F, coating andparticle side down to a 0.125 inch thick 6 in×6 in section of glassusing a thermal film laminator (GBC Catena 35, GBC Document Finishing,Lincolnshire, Ill.). The laminated sample was allowed to cool to roomtemperature. The T50 liner was then removed, leaving the particlesarranged on the substrate.

Example 4 Particle Delivery Film with Integrated Edge Seal

A coating solution was prepared by dissolving enough of QPAC 40 in 1-3dioxolane to produce a final weight percent of 5% QPAC 40. The coatingsolution was delivered at a rate of 30 cm³/min to a 10.2 cm (4 inch)wide slot-type coating die. After the solution was coated on thebackside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, thecoated film traveled approximately 2.4 m (8 ft) before entering a 9.1 m(30 ft) conventional air floatation drier with all 3 zones set at 65.5°C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10ft/min) to achieve a coated film with a wet coating thickness of about80 micrometers.

A slurry was prepared consisting of glass particles and QPAC 40 in MEK.A screen-print mesh was prepared by masking a 5.75 in×5.75 in squarewith tape on the top of the screen. A second solid square 5.25 in×5.25in was created with tape and centered in the first square to create asquare opening in the mesh 0.25 in wide. A section of the coated filmlarger than 6 in×6 in was placed under the screen, and the screenpressed and held against the coated film with weights. The preparedslurry was forced through the opening in the screen-print mesh with foamapplicators. The screen was removed, and the slurry was allowed to dryovernight at room temperature, creating an edge seal delivery film.

A piece of the edge seal delivery film slightly larger than 6 in×6 inwas placed on a hotplate held at 50° C. Grade 36+ shaped abrasiveparticles prepared according to the disclosure of U.S. Pat. No.8,142,531 having a side length of about 0.8 mm and about 0.2 mm thick,and a sidewall angle of 98 degrees. The particles were pressed into theheated film in a grid with 2 cm spacing, creating a particle deliveryfilm. The particle and edge seal delivery film was removed from thehotplate and brought to room temperature.

The cooled particle and edge seal delivery film was laminated at 230°F., coating and particle side down to a 0.125 inch thick 6 in×6 insection of glass using a thermal film laminator (GBC Catena 35, GBCDocument Finishing, Lincolnshire, Ill.). The laminated sample wasallowed to cool to room temperature. The T50 liner was then removed,leaving the particles arranged on the substrate, and the edge sealarranged around the perimeter of the glass.

Example 5 Landless Replication Via Mask Method

A coating solution was prepared by dissolving enough of QPAC 40 in1-3-dioxolane to produce a final weight percent of 5% QPAC 40. Thecoating solution was delivered at a rate of 30 cm³/min to a 10.2 cm (4inch) wide slot-type coating die. After the solution was coated on thebackside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, thecoated film traveled approximately 2.4 m (8 ft) before entering a 9.1 m(30 ft) conventional air floatation drier with all 3 zones set at 65.5°C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10ft/min) to achieve coated film with a wet coating thickness of about 80micrometers.

A 2 mil perforated film was prepared by laser cutting (LaseX, Inc.,White Bear Lake, Minn.) 500 micron diameter holes spaced on 2 cm centersinto an 0.008 inch polypropylene film. The perforated film was laminatedat 230° F., coating side down to a section of the coated film using athermal film laminator (GBC Catena 35, GBC Document Finishing,Lincolnshire, Ill.). The laminated sample was allowed to cool to roomtemperature.

The wells in the film were then filled with FILTEK Supreme+ 5032W2009-04 by applying the FILTEK Supreme+ paste to the film and doctoringoff the excess with the edge of a glass microscope slide. The resultingfilm was then cured under germicidal lamps for five minutes.

The perforated film was peeled off of the substrate, leaving a particledelivery film that contained particles of cured FILTEK Supreme+ paste inthe size and position of the holes in the perforated film.

The cooled particle delivery film was laminated at 230° F., coating andparticle side down to a glass microscope slide using a thermal filmlaminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.).The laminated sample was allowed to cool to room temperature. The T50substrate was then removed, leaving the particles arranged on the glass,held by the QPAC 40 layer.

Example 6 Landless Replication with Adhesive Layer Via Mask Method

A coating solution was prepared by dissolving enough of QPAC 40 in 1-3dioxolane to produce a final weight percent of 5% QPAC 40. The coatingsolution was delivered at a rate of 30 cm³/min to a 10.2 cm (4 inch)wide slot-type coating die. After the solution was coated on thebackside of a 0.051 mm (0.002 inch) thick T50 silicon release liner, thecoated film traveled approximately 2.4 m (8 ft) before entering a 9.1 m(30 ft) conventional air floatation drier with all 3 zones set at 65.5°C. (150° F.). The substrate was moving at a speed of 3.05 m/min (10ft/min) to achieve coated film with a wet coating thickness of about 80micrometers.

A 2 mil perforated film was prepared by laser cutting (LaseX, Inc.,White Bear Lake, Minn.) 500 micron diameter holes spaced on 2 cm centersinto an 0.008 inch polypropylene film. The perforated film was laminatedat 230° F., coating side down to a section of the previously coated filmusing a thermal film laminator (GBC Catena 35, GBC Document Finishing,Lincolnshire, Ill.). The laminated sample was allowed to cool to roomtemperature.

The wells in the film were then filled with FILTEK Supreme+ 5032W2009-04 by applying the FILTEK Supreme+ paste to the film and doctoringoff the excess with the edge of a glass microscope slide. The resultingfilm was then cured under germicidal lamps for five minutes. A secondlayer of FILTEK Supreme+ 5032W 2009-04 by applying the FILTEK Supreme+paste to the film and doctoring off the excess with a spatula, leaving athin layer of uncured FILTEK Supreme+ paste on top of the cured layer,imparting adhesion to the sample.

The perforated film was peeled off of the substrate, leaving a particledelivery film that contained particles of cured FILTEK Supreme+ paste inthe size and position of the holes in the film, with a thin layer ofuncured FILTEK Supreme+ paste on the top of the columns.

The cooled particle delivery film was laminated at 230° F., coating andparticle side down to a glass microscope slide using a thermal filmlaminator (GBC Catena 35, GBC Document Finishing, Lincolnshire, Ill.).The laminated sample was allowed to cool to room temperature. Theresulting laminate was then cured under germicidal lamps for fiveminutes. The T50 liner and QPAC 40 substrate was then removed, leavingthe particles arranged on the glass.

Example 7 Coated Encapsulated Pillars

A particle delivery film was created by applying FILTEK Supreme+ pastedrop wise to 2 mil unprimed PET and grade 36+ shaped abrasive particlesprepared according to the disclosure of U.S. Pat. No. 8,142,531 having aside length of about 0.8 mm and about 0.2 mm thick, and a sidewall angleof 98 degrees. The particles were pressed into the resin. The sample wascrosslinked using 4 passes of ultraviolet irradiation (RPC Industries UVProcessor QC 120233AN/DR, Plainfield, Ill.) at 50 f pm in air. Anyexcess resin surrounding the pillars was removed using a razor blade tocreate planarized pillars. The planarized pillars were released from thePET by flexing it in a tight radius.

A light microscope image at 50× of the FILTEK Supreme+ paste planarizedslip cast pillar showed that the pillar appeared as a light core with anopaque nanoparticle resin planarizing one surface.

The invention claimed is:
 1. A pillar delivery film, comprising: asupport film; a sacrificial material layer on the support film; and aplurality of pillars, wherein each pillar is at least partially embeddedin the sacrificial material layer, each pillar includes a draft angle αbetween a face and a sloping sidewall and the draft angle is betweenabout 95° to about 130° degrees, wherein the sacrificial material layeris discontinuous and in discrete regions around the pillars, and whereinthe sacrificial material layer is capable of being removed from thepillars while leaving the pillars substantially intact.
 2. The deliveryfilm of claim 1, wherein the sacrificial material layer is athermoplastic or thermoset material.
 3. The delivery film of claim 1,wherein the pillars are comprised of sintered ceramic bodies.
 4. Thedelivery film of claim 1, further comprising an edge seal on the supportfilm and surrounding the pillars.
 5. The delivery film of claim 1,further comprising a functional coating on a surface of the pillars. 6.The delivery film of claim 5, wherein the functional coating comprisesan adhesive.
 7. A pillar delivery pocket film, comprising: a supportfilm, wherein a plurality of pockets are formed within the support film;and a sacrificial material located within the pockets of the supportfilm; and a plurality of pillars at least partially embedded in thesacrificial material in the pockets of the support film, wherein thesacrificial material within the pockets is capable of being removed fromthe pillars while leaving the pillars substantially intact.
 8. Thedelivery pocket film of claim 7, wherein the sacrificial material is athermoplastic or thermoset material.
 9. The delivery pocket film ofclaim 7, wherein the pillars are comprised of sintered ceramic bodies.10. The delivery pocket film of claim 7, further comprising an edge sealon the support film and surrounding the pillars.
 11. The delivery pocketfilm of claim 7, wherein the sacrificial material is only located in thepockets of the support film.
 12. The delivery pocket film of claim 7,wherein the sacrificial material is a continuous layer on the supportfilm.
 13. The delivery pocket film of claim 7, further comprising aliner over the pillars on a side of the pillars opposite the supportfilm.
 14. The delivery film of claim 7, wherein each pillar includes adraft angle α between a face and a sloping sidewall.
 15. The deliveryfilm of claim 14, wherein the draft angle α is between about 95° toabout 130° degrees.